Reel assembly



June 28, 1966 J. E. BERNARD, JR 3,258,545

REEL AS SEMBLY Original Filed June 5, 1959 2 Sheets-Sheet 1 a '3 John E.Bernard, Jr.

June 28, 1966 J. E- BERNARD, JR

REEL AS SEMBLY zlwucm lob John E. Bernard, Jr.

fitter/um 2 Sheets-Sheet 2 Original Filed June 5, 199

United States Patent 3,253,545 REEL ASSEMBLY John E. Bernard, Jr.,Salem, Va., assignor, by mesne assignments, to Orland W. Phillips,Copper Valley, Va., doing business as Phillip Welding Originalapplication June 3, 1959, Ser. No. 817,786, new Patent No. 3,106,366,dated Oct. 8, 1963. Divided and this application Jan. 8, 1963, Ser. No.250,037 8 Claims. (Cl. 191-12.2)

This application is a division of my copending application Serial No.817,786, filed June 3, 1959, now Patent No. 3,106,366, issued October 8,1963.

This invention relates to reel assemblies and has for an object theprovision of an improved reel assembly for making contact with one ormore conductors.

Another object of the invention is to provide an improved reel assemblyfor making an explosion-proof contact with a hot electrical lead.

A further object of the invention is to provide an improved currentcollector for electrically connecting relatively rotating terminalswhich is explosion-proof and will continue to function effectivelydespite a failure in its main contact means.

Other objects and advantages of the invention will appear hereafter inthe detailed description, be particularly pointed out in the appendedclaims and be illustrated in the accompanying drawings, in which:

FIGURE 1 is a front elevational view of a preferred embodiment of thereel assembly of the present invention;

FIGURE 2 is an end elevational view of the drawing and of the assembly;

FIGURE 3 is a fragmentary end elevational view of the opposite end ofthe assembly;

FIGURE 4 is a vertical sectional view taken along the lines 44 of FIGURE1;

FIGURE 5 is a fragmentary vertical sectional view on an enlarged scaletaken along the lines 5-5 of FIGURE 3;

FIGURE6 is a vertical sectional view taken along the lines 6-6 of FIGURE5;

FIGURE 7 is a vertical sectional view on a reduced scale taken along thelines 77 of FIGURE 5;

Referring now in detail to the drawings in which like referencecharacters designate like parts, the improved reel assembly of thepresent invention in the exemplary form illustrated is designed for usein reeling a plurality of insulated electrical cables, such as the leadsbetween a welding machine and a welding head, and to transfer current toeither cable during reeling in such manner as to prevent arcing and sosuit the assembly for installations where proof against arc-inducedexplosions is essential.

The improved reel assembly is comprised of a frame or stand 1 rotatablymounting one or more reels, the frame being suitably adapted formovement or for fixed installation depending on the requirements of theparticular use for which the assembly is designed. For reelingelectrical cable, the reel assembly will generally have a plurality ofreels, one for each of the leads between an energy source and the deviceto be operated. Also, if the installation calls for direct current andgrounding at the work is feasible, a single reel for the one lead thenrequired will sufiice. In either case, it is intended that a lead orcable remain on its reel and make contact through the assembly with alead from the energy source or ground, as appropriate. Consequently, itis desirable that each reel or at least its core be made of aluminum orlike non-magnetizable material, to prevent induction of magnetism in thecore by current flowing through any of the coils of the lead wrappedtherear-ound.

Patented June 28, 1966 The reel assembly of the illustrated embodimentis particularly designed for use in reeling electrical cabletransmitting current between a welding machine (not shown) and a Weldinghead (not shown) and serves both to store the cable and to pay it outand take it up as needed for the welding head to reach the work to bewelded. Since the current used in welding is direct, with one leadpositive or negative, depending on the welding conditions, it ispossible for the reel assembly to have but a single reel. However, thereel assembly has been illustrated with two reels, a first 2 for reelingby a positive or negative, hereinafter termed hot, lead or cable 3, anda second 4 for reeling a ground lead or cable 5, in case it isinconvenient to ground the Welding head at the work. The reels 2 and 4are mounted concentrically or coaxially and in axial or longitudinallyspaced relation on the frame 1. For such mounting, the frame 1conveniently has a pair of end uprights 6 and an intermediate upright 7,in longitudinal alignment with each other and each suitably tubular andbent into a somewhat inverted U-shape, with its legs 8 downwardlydivergent. Connected at the top by longitudinal braces 9, the uprights 6and 7 are connected at the bottom by a pair of transversely spacedchannel irons or other suitable feet 10, each fixed to the legs 8 of theuprights at one side of the frame 1, the feet, if not used as a base forfixing the frame to a foundation or mounting it on suitable wheels forgeneral mobility, conveniently serving as skids for limited mobility.

Each of the illustrated reels 2 and 4 is formed of a pair of inner andouter axially or longitudinally spaced end wheels, discs or flangesconnected by circumferentially spaced slats 11 together forming itsnon-magnetizable core 12, the inner and outer wheels of the first reel 2being designated as 13 and 14, respectively, and of the second reel 4 as15 and 16, respectively.

Each of the reels 2 and 4 is contained longitudinally between theintermediate upright 7 and one of the end uprights 6 and the second orground reel 4 is rotatably mounted entirely on a shaft or axle 17. Inturn, the shaft 17 extends from one end of the frame 1 through and isjournalled or rotatably mounted in a pair of axially or longitudinallyspaced bearings or bushings 18, one carried by the end upright 6 at thatend and the other by the intermediate upright 7, and each convenientlysupported on and bolted or otherwise secured or fixed to transverse orcross braces 19 connecting and fixed to or rigid with the legs 8 of itsupright. Extending through axially bored hubs 20 in the end wheels 15and 16 of the second reel 4 with a fit such that the reel is free torotate relative to it, the shaft 17 also extends into the adjoining endof the first reel 2 and correspondingly fits an axially bored hub 21 ofor on the inner wheel 13 of that reel, so as rotatably to mount that endof that reel.

Were the reel assembly designed simply for selectively driving the pairof reels 2 and 4, the shaft 17 could be extended the length of the frame1 and rotatably mount both ends of both reels. However, an importantfeature of this invention is an explosion-proof connection through theouter end Wheel 14 of the first reel 2 between the hot lead 3 and acorresponding lead 22 from the welding machine to the frame 1 and such aconnection requires a different rotatable mounting of that wheel on theadjoining end upright 6. Accordingly, the illustrated shaft 17terminates slightly beyond the hub 21 of the inner wheel 13 of the firstreel 2 and its function for the outer end wheel 14 is performed by ahollow stub axle or trunnion 23 fixed or secured to or rigid with theouter wheel and projecting or extending therebeyond into and rotatablyseated or journalled in a cylindrical bore 24 in a housing or casing 25carried by the adjoining end upright.

In its preferred form, the hollow stub axle 23 is an outwardly cuppedend plate or member having a central aperture 26 aligning with acorresponding central or axial aperture 27 in the outer wheel 14 andsecured as by bolting to the latters'outer end face 28. The end plate isgiven its cup shape by an integral axially outstanding annular orcylindrical, marginal or peripheral flange or skirt 29, concentric withthe hub 21 of the inner wheel 13 and having its rim 30 rotatably seatinin a shouldered inner end portion 31 of the bore 24 in the housing 25.For facilitating relative rotation of the stub axle 23 and housing 25,there preferably are provided antifriction means in the form of aplurality of balls 32 interposed between and riding in confronting racesor grooves 33 formed in the side wall 34 of the bore 24 and the rim 30of the flange 29, the balls, which readily may be inserted andlubricated through a normally plugged radial port 35 in the housing,also serving to lock the first reel 2 and the housing against relativeaxial movement. Supporting the outer end of the first reel 2, thehousing 25 may be carried or supported on the frame 1 in the same manneras the bushings 18 by bolting or otherwise fixing or securing it totransverse or cross braces 36 extending between and rigidly connectingthe legs 8 of its end upright 6.

The housing 25 not only rotatably mounts the outer end wheel 14 of thefirst reel 2, but also serves to shield, house, enclose or contain thecurrent collector 37 of the aforementioned explosion-proof connection orconnecting means, now designated as 38, between the hot lead 3 on thefirst reel 2 and the corresponding lead 22 from the welding machine. Tothis end, the cylindrical bore 24, which extends axially through thehousing 25 and is concentric or coaxial with the shaft 17, is closed atits outer end by an insulating block or disc 39, the latter convenientlyfitting in a shouldered recess in the outer end portion of the bore andbeing screwed or otherwise suitably secured to the housing. The oppositeor inner end of the central chamber or cavity 40 in the housing 25 isclosed by an inner insulating block or disc 41 which seats in theoutwardly facing socket 42 in the end plate 23 bounded by the lattersperipheral flange 29 and is screwed or otherwise secured to the endplate so as to rotate therewith.

Each of the insulating blocks 39 and 41 carries or mounts and insulatesfrom the frame 1 and first reel 2 one of a pair of outer and inner bolts43 and 44, respectively, the heads 45 of which are contained in axiallyspaced relation in the chamber 40 and the stems 46 of which projectoppositely therefrom through their respective insulating blocks. Theouter and inner bolts 43 and 44 preferably are substantially concentricwith the first reel 2 and, in the threaded end portions of their stems46 projecting beyond their insulating blocks, provide relativelyrotatable outer and inner threaded blocks, provide relatively rotatableouter and inner threaded terminal posts 47 and 48 to which, throughsuitable nuts 49 and washers 50, the contiguous ends or terminals of thehot lead 3 and the outside lead 22 from the welding machine areconnected. Projecting or extending through the central apertures 26 and27 in the end plate 23 and outer wheel 14, the inner terminal post 48and its associated nuts and washers are insulated therefrom by the airgap provided by the intervening radial spacing.

Transmission of current between the terminal bolts 43 and 44 andtherethrough between the hot and outside leads 3 and 22 is the functionof the contact el'e ments of the current collector 37. Housed orcontained in the chamber 40 in the housing 25, the contact elementsinclude a preferably flat and circular inner contact disc or plate 51 ofconducting material encircling the stem 46 and clamped by the head 45 ofthe inner terminal bolt 43 to the inner insulating block 41, so as torotate therewith on rotation of the first reel 2. A second or outer,preferably also circular, disc or plate 52 of conducting material,spaced axially from the first and encircling the stem 46 of the outerterminal bolt 44 is clamped by the latter against the outer insulatingblock 39. Between these two discs, the outer 52 stationary and the inner51 rotatable, is interposed a third or intermediate, preferably circulardisc or plate 53 of conducting material having a flat inner face 54adapted to slide on and have surface contact with the confronting outerface 55 of the inner contact disc 51 and centrally apertured as at 56loosely to receive and be rotatable relative to the head 45 of the innerterminal bolt 43.

Electrical contact or connection between the intermediate and outercontact discs 53 and 52 is made mainly by a plurality ofcircumferentially spaced prongs or studs 57 projecting axially from oneof these members, here the intermediate disc, toward the other memherand each seating in or interfitting with one of a plurality ofcorrespondingly arranged and projecting socketed protuberances 58 in theother member. Three in number in the illustrated embodiment and equallyspaced, these interfitting studs 57 and protuberances 58 serve not onlyas the main contacts between the outer and intermediate discs 52 and 53,but to center and hold the latter disc against rotation. At the sametime, they serve, with intervening, circumferentially spaced pairs ofconfronting bosses 59 on the two members, to locate or position aplurality of coil springs 60, each encircling one of the main contactsor pairs of bosses and acting axially between the outer and intermediatediscs to urge the latter into contact with the inner disc 51. Not onlyare these springs 60 the means by which contact between the intermediateand inner discs 53 and 51 is maintained during their relative rotation,but by making them of Phosphor-bronze or like resilient conductingmaterial of suflicient gauge, the springs are enabled to serve asauxiliary contacts between the outer and intermediate discs in case offailure in a main contact due to breakage or Wear.

With contact between the outer and inner terminal bolts 44 and 43established at all times by the several contact discs 51, 52 and 53, anypossible arcing in the connecting is prevented by filling the centralchamber with transformer oil or like non-conducting fluid so as toimmerse the contact discs in that medium, the chamber being filledthrough a suitable filler hole 61 extending radially through the top ofthe housing 25 and normally closed by a breather plug or like suitablemeans 62 to permit expansion and contraction of the oil. To enable theoil to be held without leakage in the reservoir 62, the joints betweenthe various elements about the chamber are sealed by O-rings or likesuitable gaskets 63.

While, by contrast with the hot lead 3 on the first reel 2, the groundlead 5 on the second reel 4 is grounded through the latter and the frame1 and presents no particular arcing problem, it nonetheless is desirableto ensure that the lead will be grounded from the reel directly to theframe, rather than through the shaft 1. For this purpose, there isprovided a collecting ring 64, split for adjustability and slidablyencircling a central or axial annular flange 65 on the outer wheel 16 ofthe second reel 4, the ring having an integral lug 66 of substantialarea through which it is bolted or otherwise directly secured to one ofthe cross braces 19 of the adjoining end upright 6. With the innerterminal of the ground lead 5 connected to a binding post 67conveniently provided for that purpose on one of the slats 11 of thesecond reel, current will thus flow from the ground lead through thereel and the frame 1 to the feet 10 and therethrough to the ground. Incase the frame itself is not directly grounded due to the nature of itsmounting or the particular surface on which it rests, it usually will bedesirable to provide a binding post 68 on one of the feet 10 for a cableconnection, indicated at 69, between the frame and a suitable ground.

With each of the hot and ground cables 3 and 5 running through one of apair of sets of guide rollers 70 suitably mounted for that purpose onone side of the frame 1, the reels 2 and 4 preferably are madeselectively drivable so that the cables may be reeled out or in, eithertogether or independently, in the manner described in my copendingapplication Ser. No. 817,786, filed June 3, 1959.

From the above-detailed description, it will be apparent that there hasbeen provided an improved reel assembly capable of providing anexplosion-proof connection between a cable wound on a reel and a sourceof power. It should be understood that the described and disclosedembodiment is merely exemplary of the invention and that allmodifications are intended to be included which do not depart fromeither the spirit of the invention or the scope of the appended claims.

Having described my invention, I claim:

1. A reel assembly comprising a frame, a reel rotatably mounted at oneend on said frame, a housing mounted on said frame and rotatablymounting an opposite end of said reel, and an oil-immersed currentcollector enclosed in said housing for electrically connecting a cableon said reel with a power source.

2. A reel assembly comprising a frame, a reel rotatably mounted at oneend on said frame, and a current collector for electrically connecting acable on said reel to a power source, said collector including a housingmounted on said frame and rotatably mounting an opposite end of saidreel, a contact disc in said housing and connected for rotation withsaid reel, and disc means in and restrained against rotation relative tosaid housing and yieldably urged into facial engagement with saidcontact disc.

3. A reel assembly comprising a frame, a reel rotatably mounted at oneend on said frame, and a current collector for electrically connecting acable on said reel to a power source, said collector including a housingmounted on said frame and mounting an opposite end of said reel, anoilfillable sealed chamber in said housing, a contact disc member insaid chamber and connected for rotation with said reel, a stationarycontact disc in said chamber, and disc means in said chamberintermediate said discs for transmitting current therebetween, said discmeans being restrained against rotation relative to one and yieldablyurged into facial engagement with the other of said discs.

4. A reel assembly comprising a frame, a reel, an axle on one end ofsaid reel rotatably mounted on said frame, and a current collector forelectrically connecting a cable on said reel to a power source, saidcollector including a housing mounted on said frame and having a borerotatably receiving an axle on the opposite end of said reel,antifriction means interposed radially between and interlocking saidhousing and axle against relative axial movement, a contact disc in saidbore and connected for rotation with said reel, and disc means in andrestrained against rotation relative to said housing and yieldably urgedinto facial engagement with said contact disc.

5. A reel assembly comprising a frame, a reel rotatably mounted at oneend on said frame and having a hollow stub axle on an opposite endthereof, and a current collector for electrically connecting a cable onsaid reel to a power source, said collector including a housing mountedon said frame, an axial bore extending through said housing androtatably seat-ing said axle in an inner end thereof, a pair of axiallyspaced insulating blocks each secured to one of said housing and axle,said blocks and axle together bounding and sealing ends of anoil-fillable chamber in said housing, a pair of terminal bolts eachmounted on one of and extending oppositely through said insulatingblocks, a contact disc in said chamber and clamped by one of said boltsto one of said blocks, a contact disc axially spaced from said firstdisc and attached by the other bolt to the other block, and a contactdisc intermediate sa-id spaced discs, said intermediate disc beingyieldably urged into sliding engagement with one of said spaced discsand restrained against rotative move- 6 ment relative to and inelectrical contact with the other spaced disc.

6. A reel assembly comprising a frame, a reel rotatably mounted at oneend on said frame and having a hollow stub axle on an opposite endthereof, and a current collector for electrically connecting a cable onsaid reel to a power source, said collector including a housing mountedon said frame, an axial bore extending through said housing androtatably seating said axle in an inner end thereof, a pair of axiallyspaced insulating blocks each secured to one of said housing and axle,said blocks and axle together bounding and sealing ends of anoil-fillable chamber in said housing, a pair of terminal bolts eachmounted on one of and extending oppositely through said insulatingblocks, a contact disc in said chamber and clamped by one of said boltsto one of said blocks, a contact disc axially spaced from said firstdisc and attached by the other bolt to the other block, a contact discintermediate and slidably contactable with one of said spaced discs,interfitting means on said other spaced and intermediate discs forelectrically connecting and restraining said discs against relativerotation, and spring means acting axially between said other spaced andintermediate discs for urging said intermediate disc into said slidingcontact with said one spaced disc.

7. A reel assembly comprising a frame, a reel rotatably mounted at oneend on said frame and having a hollow stub axle on an opposite endthereof, and a current collector for electrically connecting a cable onsaid reel to a power source, said collector including a housing mountedon said frame, an axial bore extending through said housing androtatably seating said axle in an inner end thereof, a pair of axiallyspaced insulating blocks each secured to one of said housing and axle,said blocks and axle together bounding and sealing ends of anoil-fillable chamher in said housing, a pair of terminal bolts eachmounted on one of and extending oppositely through said insulatingblocks, a contact disc in said chamber and clamped by one of said boltsto one of said blocks, a contact disc axially spaced from said firstdisc and attached by the other bolt to the other block, a contact discintermediate and slidably contactable with one of said spaced discs,interfitting means on said other spaced and intermediate discs forelectrically connecting and restraining said discs against relativerotation, and current conducting spring means acting axially betweensaid other spaced and intermediate discs for urging said intermediatedisc into said sliding contact with said one spaced disc.

8. A reel assembly comprising a frame, a reel rotatably mounted at oneend on said frame and having a hollow stub axle on an opposite endthereof, and a current collector for electrically connecting a cable onsaid reel to a power source, said collector including a housing mountedon said frame, an axial bore extending through said housing androtatably seating said axle in an inner end thereof, a pair of axiallyspaced insulating blocks each secured to one of said housing and axle,said blocks and axle together bounding and sealing ends of anoil-fillable chamber in said housing, a pair of terminal bolts eachmounted on one of and extend-ing oppositely through said insulatingblocks, a contact disc in said chamber and clamped by one of said boltsto one of said blocks, a contact disc axially spaced from said firstdisc and attached by the other bolt to the other block, a contact discintermediate and slidably contactable with one of said spaced discs,interfitting means on said other spaced and intermediate discs forelectrically connecting and restraining said discs against relativerotation, and a plurality of circumferentially spaced current conductingsprings connecting and act-ing axially between said other spaced andintermediate discs for urging said intermediate disc into said slidingcontact with said one spaced disc, certain of said springs encirclingand being positioned by said interfitting means.

(References on following page) References Cited by the Examiner UNITEDSTATES PATENTS Sessions 19112.2

Coseo 19112.2

Heim 19112.2

Levin 19112.2 Judson.

Tornblom 19112.2 Jeffery et a1 19112.2 1O Shoflner 19112.2 Arthur200--150 X Burns 200-153 Cooper et a1 3395 Sciaky 339-5 Vandenberg240--8.18 Seeloof et a1 339-5 X Seeloof 3395 Fisher et a1 3395 XFilipczak 3395 Appleton 19112.2

FOREIGN PATENTS France.

ARTHUR L. LA POINT, Primary Examiner.

JAMES S. SHANK, Examiner.

S. T. KRAWCZEWICZ, Assistant Examiner.

1. A REEL ASSEMBLY COMPRISING A FRAME, A REEL ROTATABLY MOUNTED AT ONEEND ON SAID FRAME, A HOUSING MOUNTED ON SAID FRAME AND ROTATABLYMOUNTING AN OPPOSITE END OF SAID REEL, AND AN OIL-IMMERSED CURRENTCOLLECTOR ENCLOSED IN SAID HOUSING FOR ELECTRICALLY CONNNECTING A CABLEON SAID REEL WITH A POWER SOURCE.